Flow block sealing methods

Patent metadata

Field	Value
Publication number	US-12370614-B2
Application number	US-202217661458-A
Country	US
Kind code	B2
Filing date	Apr 29, 2022
Priority date	Apr 29, 2022
Publication date	Jul 29, 2025
Grant date	Jul 29, 2025

Abstract

A pulsed electrochemical machining (pECM) system including a tool body defining a tool axis and a proximal end and a distal end. The tool body includes one or more electrodes, each of the one or more electrodes defining a working surface at the distal end of the tool axis configured to face a workpiece. Electrolyte at least partially fills an interelectrode gap defined by the working surface at the distal end of the tool axis and a target surface of the workpiece. A first flow block coupled to the tool body and a second flow block coupled to the workpiece are configured to form at least one seal surrounding at least a portion of a perimeter of the interelectrode gap, and the at least one seal is configured to reduce or eliminate flow of the electrolyte out of the portion of the perimeter of the interelectrode gap.

First claim

The invention claimed is:

1. A pulsed electrochemical machining (pECM) system, comprising:
a tool body defining a tool axis and a proximal end and a distal end, the tool body comprising one or more electrodes, each of the one or more electrodes comprising an electrically conductive material and defining a working surface at the distal end of the tool axis configured to face a workpiece;
an interelectrode gap defined by the working surface at the distal end of the tool axis and a target surface at a proximal end of the workpiece;
an electrolyte configured to be charged by the one or more electrodes and at least partially fill the interelectrode gap;
a first flow block coupled to the tool body;
a cathode seal body surrounding a perimeter of the tool body, the cathode seal body being configured to form a seal around the perimeter of the tool body such that the electrolyte is prevented from flowing along sides of the tool body adjacent to the first flow block, wherein the cathode seal body is configured to be disposed in a cathode seal collar defined by the first flow block, and wherein the cathode seal body comprises a groove defined along at least a portion of the perimeter of the cathode seal body and configured to receive a cathode seal body gasket, wherein the cathode seal body gasket forms the seal between the cathode seal body and the first flow block; and

a second flow block coupled to the workpiece, wherein the first flow block and second flow block are configured to form at least one seal surrounding at least a portion of a perimeter of the interelectrode gap, wherein the at least one seal is configured to reduce or eliminate flow of the electrolyte out of the portion of the perimeter of the interelectrode gap.

2. The pulsed electrochemical machining system of claim 1 , wherein the cathode seal body is formed in one piece by additive manufacturing.

3. The pulsed electrochemical machining system claim 1 , further comprising at least one gasket disposed between the first flow block and second flow block.

4. The pulsed electrochemical machining system of claim 3 , wherein the first and second flow blocks are mechanically coupled together by at least one fastener such that pressure is applied to the at least one gasket disposed between the flow blocks.

5. The pulsed electrochemical machining system of claim 1 , wherein the cathode seal body gasket comprises an o-ring, and wherein the o-ring forms the seal between the cathode seal body and the first flow block.

6. The pulsed electrochemical machining system of claim 1 ,
wherein the tool body defines an outer perimeter defining a shape, and the cathode seal body defines an outer perimeter defining a different shape.

7. The pulsed electrochemical machining system of claim 1 , further comprising at least one seal bar coupled to at least one of the first or second flow blocks, the seal bar comprising at least one adjustable seal pad configured to adjustably extend from a recess within the seal bar.

8. The pulsed electrochemical machining system of claim 1 , wherein the workpiece is configured to form a part of the at least one seal formed by the first flow block and the second flow block.

9. The pulsed electrochemical machining system claim 1 , wherein the at least one seal surrounds the entire perimeter of the interelectrode gap except for an electrolyte inlet and an electrolyte outlet.

10. A method for pulsed electrochemical machining (pECM) a workpiece, comprising:
positioning a working surface of one or more electrodes relative to a target surface of a workpiece to remove material from the target surface of the workpiece;
forming a seal surrounding at least a portion of a perimeter of an interelectrode gap, the at least one seal configured to reduce or eliminate flow of an electrolyte out of the portion of the perimeter of the interelectrode gap, the at least one seal formed by a first flow block coupled to a tool body and a second flow block coupled to the workpiece, wherein forming the seal comprises:
positioning a cathode seal body surrounding a perimeter of the tool body, the cathode seal body preventing electrolyte from flowing along sides of the tool body adjacent to the first flow block, and wherein positioning the cathode seal body includes
disposing the cathode seal body in a cathode seal collar defined by the first flow block, wherein the cathode seal body comprises a groove defined along at least a portion of the perimeter of the cathode seal body, the groove mechanically supporting a cathode seal body gasket, wherein the cathode seal body gasket forms a seal between the cathode seal body and the first flow block;

delivering the electrolyte into the interelectrode gap between the working surface of the one or more electrodes and a target surface of the workpiece; and
generating a pulsed direct current between one or more electrodes of a machining tool and the workpiece, wherein the machining tool comprises the tool body defining a tool axis, the tool body comprising the one or more electrodes, each of the one or more electrodes comprising an electrically conductive material and defining the working surface at a distal end of the tool axis configured to face the workpiece.

11. The method of claim 10 , further comprising mechanically coupling the first flow block and the second flow block together to form the seal surrounding at least a portion of the perimeter of the interelectrode gap.

12. The method of claim 11 , wherein forming a seal around the tool body by surrounding at least a portion of the perimeter of the tool body with a cathode seal body includes sliding the cathode seal body over a proximal or distal end of the tool body.

13. The method of claim 10 , further comprising:
positioning a gasket between the first flow block and the second flow block.

14. The method of claim 13 , further comprising:
mechanically coupling the first flow block and the second flow block by tightening at least one fastener which applies pressure to the gasket positioned between the first flow block and the second flow block.

15. The method of claim 10 , further comprising:
positioning an o-ring in the groove defined along at least a portion of the perimeter of the cathode seal body to form the seal between the cathode seal body and the first flow block.

16. The method of claim 10 , further comprising:
coupling at least one seal bar to at least one of the first flow block or the second flow block, the seal bar comprising at least one adjustable seal pad configured to adjustably extend from a recess within the seal bar.

Assignees

• Rolls Royce Corp

Inventors

• Garner Rusty M
• Ward Damon

Classifications

• B23H7/18

  for maintaining or controlling the desired spacing between electrode and workpiece · CPC title

• B23H2300/10

  Pulsed electrochemical machining · CPC title

• B23H11/00

  Auxiliary apparatus or details, not otherwise provided for · CPC title

• B23H3/04

  Electrodes specially adapted therefor or their manufacture (B23H9/00 takes precedence) · CPC title

• B23H7/30 Primary

  Moving electrode in the feed direction (B23H7/32 takes precedence) · CPC title